SWF DV/DT Solutions Sinewave Filters N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI 53051 P. (262) 754-3883 F. (262) 754-3993 www.apqpower.com
Does your application use variable frequency drives for improved motor control? Have you experienced premature motor failure? Maximize your motors life with an SWF Solution from APQ LLC. Protect the heart of your application today! Eliminate premature insulation breakdown Return the voltage to a near sine wave Meet Nema MG-1 standards Limit peak voltage and increase voltage rise time Reduce motor noise and vibration Attenuate the PWM inverter switching frequency Protect submersible pumps Eliminate voltage reflection points Maximize application power Utilize a low voltage drive, step up transformer, and medium voltage motor Increase cable distances Centrally locate VFDs, regardless of motor location Improve system uptime Reduce application downtime Decrease Equipment Replacement Costs Increase equipment life spans with efficient power usage The information provided within this product catalog is subject to change without notice. For complete product details, please contact APQ, LLC. 2 SWF DV/DT Solutions Sinewave Filters
THE CHALLENGE: PROTECT MOTOR INSULATION IN LONG LEAD AND SUBMERSIBLE APPLICATIONS Engineered Power Quality Variable Frequency Drives, commonly referred to as VFDs, allow for the more efficient use of energy in a myriad of applications. The technology utilizes PWM, or pulse width modulation, to simulate an AC sine wave with numerous fast rising pulses. The ability to vary both frequency and voltage allows for more precise control of motor speed. However, these pulses can lead to voltage peaks that exceed the insulation rating of the motor windings. The excessive peak voltage typically impacts the first few turns of the motor windings, causing damage and premature failure. The SWF DV/TV Solutions PWM to Sine Wave Conversion The SWF DV/DT Solution output is nearly a sine wave, eliminating the threat of excessive peak voltages. This allows for the use of either an inverter duty or non-inverter duty motor within any given VFD application. Through the use of PWM rated reactors and rugged harmonic rated capacitors, the PWM switching frequency is attenuated. When properly adjusted for voltage drop, lead lengths can extend beyond 15,000 feet. Optimized for Industry APQ SWF DV/DT Solutions are intended for motor protection, especially in applications with long motor cable lengths. These high performance filters virtually eliminate the harmful effects of voltage reflection by establishing a near sine wave for the motor. Many industrial applications do not run at full load at all times, including fans and pumps. These variable torque applications have motor speeds that are often in the range of 50% to 70% speed, resulting in extended operation at lower load current. As such, the SWF DV/DT Solutions are optimized for real world conditions, with typical 5% voltage drop at 70% rated load current. Designs for Any Carrier Frequency The standard designs for the SWF DV/DT Solutions focus on 2.5 khz output carrier frequency and 5 khz output carrier frequency. APQ can design a solution for any PWM frequency desired. The 5 khz Design Type offers the most economical solution based upon cost, size, and power losses. This model is suitable for all PWM frequencies from 5 khz to 20 khz. Contact APQ for assistance with your particular application. Meet MG-1 Requirements In order to protect motors from premature insulation failure, NEMA MG-1 guidelines were developed to limit both peak voltage and voltage rise time. MG-1 Part 30 sets a limit of 1000 volts peak and a rise time of 2µ seconds for non-inverter rated motors. MG-1 Part 31 sets a limit of voltage peaks less than or equal to 3.1 times the rated voltage and a rise time of 0.1µ seconds for inverter rated motors The APQ SWF DV/DT Solutions achieve these performance levels for all VFDs and motors rated up to 690 volts. Submersible Applications Applications that require the motor cable to become submerged are especially susceptible to motor insulation degradation due to reflective voltage. The dielectric constant for water is approximately 80 times greater than the dielectric constant of air. As reflected voltage is caused by the difference in impedance between the output terminals of the VFD and the input terminals of the motor, the point where the cable enters water becomes another point of reflection. The overall impact will be voltage reflection issues that are significantly more pronounced. By applying an SWF DV/DT Solution to the output of the VFD, the reflected voltage is minimized. Various Sizes and Options SWF DV/DT Solutions can be deployed at any voltage level between 208 V and 690 V. The selection charts provided are only a portion of the available product offerings. From high frequency application designs to integrated performance monitoring systems, APQ can design the right solution for your application. Contact us today to learn how we can help you solve your voltage reflection issues. SWF DV/DT Solutions Sinewave Filters 3
THE SFW DV/DT Solution Systems LONG LIFE CAPACITORS Rugged Reliability REACTORS Precision Design OPTIONS Engineered Solutions TRANSFORMER Voltage Flexibility Systems are designed with three phase capacitors (single phase also available) Designed for rigorous and harmonic rich applications Self-healing design with segmented film technology Internal pressure switch protects each capacitor Fast connecting terminals for secure wiring for the life of the capacitor Industry leading reactor design ensures continuous high performance Balanced phase to phase inductance in all three coils PolyGap Core construction minimizes losses, audible noise, and stray magnetic fields Integrated temperature switches available upon request 2 khz - 20 khz OEM kits Open panel Enclosed NEMA Types 1, 3R, 4, 4X, 12 Reactor thermal Switch Custom designs Step-up transformers available for medium voltage motors Low voltage controls with medium voltage power Various taps for precise voltage control Voltage at the output of the VFD Voltage at the output of the SWF 2.5 khz SWF Design 5 khz SWF Design Variable Frequency Drive Transformer (Optional) Motor Variable Frequency Drive Transformer (Optional) Motor 4 SWF DV/DT Solutions Sinewave Filters
SWF DV/DT Solutions Product Specifications Electrical Specifications: System Voltage: Voltage Tolerance: ± 5% Frequency: PWM Frequency: Fundamental Frequency: Phases: Input Current Ratings: Input Power Ratings: THD-V: Voltage Drop: Efficiency: Dielectric Strength: Capacitance & Inductance: Overload Capability: Damping: Life Expectancy: 200, 208-240, 380-415, 480, 600, and 690 Volts 60 Hz / 50 Hz 2.5kHz 4 khz 5 khz 5 Hz to 90 Hz standard, others available upon request 3-phase 3 to 3000 amps 1.5 HP to 3000 HP 5% THD-V (4 khz and 5 khz Design Types) Typical 10% THD-V (2.5 khz Design Types) Typical Optimized for 5% voltage drop at 70% load Full Load Drop 7%(for 2.5 khz and 5 khz Design Types) Full Load Drop 9%(for 4 khz Design Types) 99% or higher at rated load Reactors: 3000 volts (1 minute) Capacitors: 2 x rated + 1000 volts (1 minute) Capacitance is minimized (and inductance maximized) for lowest capacitor current and lowest dv/dt 1.5x rated current (1 minute, 1 time per hour) Self damping reactors (no power resistors required) >480,000 hours at 50 C, rated power Environmental: Motor Cable Length: Ventilation: Enclosures Available: Ambient Temperature: Relative Humidity: Altitude: Unrestricted by Waveform Natural convection up to 300 HP, Forced air at 300 HP and above Indoor, Industrial, Outdoor, Open Panel, Kit -30 C to 50 C <99% non-condensing <1000 meters (3280 feet) Applicable Standards: UL: Assemblies are UL 508 / UL 508A approved Kits are UL 508 IEC / EN: CE (Low Voltage Directive): LVD certificate available NEMA Standards: MG-1 Part 30, MG-1 Part 31 Complies with EN60289, EN60076-3 SWF DV/DT Solutions Sinewave Filters 5
SWF DV/DT Solutions Reflected Wave PWM voltage consists of numerous fast rising (high dv/dt) pulses. Motors with a long cable length between the output terminals of the VFD and motor, or submersible applications, will experience a phenomenon known as voltage reflection or reflected wave. In these instances, peak voltage at the motor terminals can be as high as 1,300 volts, twice the DC bus voltage of the VFD. The excessive voltage will typically cause damage within the first few turns of the motor windings, leading to premature motor failure and expensive application down time. In applications where the motor cable is exposed to water, or other materials with a dielectric constant significantly greater than air, the peak voltages caused by reflected wave can be more pronounced. In fact, since reflected wave is a product of the impedance variance between the drive and the motor, the impedance of the cable changes at the point where it enters the water. This will cause reflection at both the water entry location and the motor terminals. Typical waveform measured at the VFD Output Typical Waveform measured at the motor terminals with no protective filter Typical Waveform measured at the motor terminals with 5 khz SWF DV/DT Solution Mitigating Reflected Wave The introduction of an SWF DV/DT Solution will eliminate excessive peak voltages and increase system uptime. Motor noise, vibration, and heating are significantly reduced by attenuating the PWM inverter switching frequency at the applied filter. The application of an SWF Solution will also reduce common mode current and motor bearing current. As these solutions meet both Part 30 and Part 31 of the MG-1 standards, either inverter or non-inverter rated motors can be used within any given application and experience an extended operating life. Typical Critical Motor Cable Length (for applications without SWF) PWM Pulse Rise Time Critical Cable Length 50 nano-sec. 3 Meters (10 ft) 0.1 µ sec. 6 Meters (20 ft) 0.5 µ sec. 31 Meters (100 ft) 1 µ sec. 62 Meters (200 ft) 2 µ sec. 125 Meters (400 ft) 6 SWF DV/DT Solutions Sinewave Filters
APPLICATIONS SWF DV/DT Solutions are designed to withstand the most rigorous applications. The right product design and configuration is available for your application. Products are offered as enclosed, open panel, or even component kits, giving you the greatest amount of flexibility for your harmonic mitigation needs. Oil & Gas HVAC High Rises Submersible Pumping Commercial Facilities Warehouses Breweries Automotive Water / Wastewater Distribution Facilities Pulp & Paper Metal Fabrication SWF DV/DT Solutions Sinewave Filters 7
SWF DV/DT Solutions Part Number System SWF 0075 480 5K 01 xxxx Product Designation Current Rating 3000 Max Amps Nominal Voltage & Freq 208 Volts@ 60 Hz = 208 240 Volts@ 60 Hz = 240 400 Volts @ 50Hz = 400 480 Volts @ 60Hz = 480 600 Volts @ 60 Hz = 600 690 Volts @ 50Hz = 690 Carrier Frequency 2.0-2.5 KHz = 2K 4.0 KHz = 4K 5.0 KHz = 5K Custom = *K Enclosure Type Type 1 = 01 Type 3R = 3R Open Panel = OP Component Kit = CK Options Leg Stand Kit = LS Reactor Thermal Switch = TH Custom Design = * SWF DV/DT Solutions Selection Requirements 1. SWF DV/DT Solutions are designed for use with one 6-pulse type variable frequency drive (VFD). This product offering is not designed to be applied with linear loads such as across-the-line started motors. 2. Solution Current Rating SWF DV/DT Solutions are current rated devices. Select the SWF with the rated current that is equal to or greater than the full load amp rating of the motor. 3. SWF DV/DT Solution Installation Refer to the Installation, Operation, and Maintenance Manual for specific information regarding the suitability of the product for a specific application in a given location. 4. SWF DV/DT Solution Installation Do not test the SWF DV/DT Solution without a connected motor load. Product damage may result. 8 SWF DV/DT Solutions Sinewave Filters
SWF DV/DT Solutions Selection Chart 240 V 5 khz Design Type 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF 0005 240 5K 01 1 5 Wall 30.0 24.0 12.0 136 SWF 0005 240 5K CK 28 SWF 0007 240 5K 01 1.5 7 Wall 30.0 24.0 12.0 138 SWF 0007 240 5K CK 30 SWF 0008 240 5K 01 2 8 Wall 30.0 24.0 12.0 138 SWF 0008 240 5K CK 30 SWF 0011 240 5K 01 3 11 Wall 30.0 24.0 12.0 138 SWF 0011 240 5K CK 30 SWF 0018 240 5K 01 5 18 Wall 30.0 24.0 12.0 153 SWF 0018 240 5K CK 45 SWF 0026 240 5K 01 7.5 26 Wall 30.0 24.0 12.0 158 SWF 0026 240 5K CK 50 SWF 0033 240 5K 01 10 33 Wall 30.0 24.0 12.0 172 SWF 0033 240 5K CK 64 SWF 0048 240 5K 01 15 48 Wall 36.0 30.0 16.0 231 SWF 0048 240 5K CK 83 SWF 0062 240 5K 01 20 62 Wall 36.0 30.0 16.0 255 SWF 0062 240 5K CK 107 SWF 0080 240 5K 01 25 80 Wall 36.0 30.0 16.0 255 SWF 0080 240 5K CK 107 SWF 0092 240 5K 01 30 92 Wall 42.0 30.0 16.0 270 SWF 0092 240 5K CK 122 SWF 0120 240 5K 01 40 120 Wall 42.0 30.0 16.0 385 SWF 0120 240 5K CK 218 SWF 0150 240 5K 01 50 150 Wall 42.0 30.0 16.0 385 SWF 0150 240 5K CK 217 SWF 0180 240 5K 01 60 180 Floor 83.0 24.0 32.0 418 SWF 0180 240 5K CK 251 SWF 0225 240 5K 01 75 225 Floor 83.0 24.0 32.0 818 SWF 0225 240 5K CK 320 SWF 0285 240 5K 01 100 285 Floor 83.0 24.0 32.0 795 SWF 0285 240 5K CK 297 SWF 0360 240 5K 01 125 360 Floor 83.0 24.0 32.0 877 SWF 0360 240 5K CK 379 SWF 0420 240 5K 01 150 420 Floor 83.0 24.0 32.0 1060 SWF 0420 240 5K CK 562 SWF 0560 240 5K 01 200 560 Floor 83.0 24.0 32.0 1019 SWF 0560 240 5K CK 521 Motor Submersible Pumps Suggested Motor Filter Application Chart 230 V motors 4-5% Reactor 400 V motors 4-5% Reactor 460 V motors 4-5% Reactor Motor Cable Length 100 ft 300 ft 500 ft 1,000 ft 15,000 ft SWF SWF SWF SWF SWF 4-5% Reactor SWF SWF n/a SWF SWF SWF SWF SWF SWF SWF SWF 575 V motors MPF SWF SWF SWF SWF 690 V motors MPF SWF SWF SWF SWF SWF DV/DT Solutions Sinewave Filters 9
SWF DV/DT Solutions Selection Chart 480 V 5 khz Series 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF 0004 480 5K 01 2 3.4 Wall 30.0 24.0 12.0 163 SWF 0004 480 5K CK 29 SWF 0006 480 5K 01 3 6.3 Wall 30.0 24.0 12.0 162 SWF 0006 480 5K CK 28 SWF 0008 480 5K 01 5 7.6 Wall 30.0 24.0 12.0 161 SWF 0008 480 5K CK 27 SWF 0011 480 5K 01 7.5 11 Wall 30.0 24.0 12.0 166 SWF 0011 480 5K CK 30 SWF 0014 480 5K 01 10 14 Wall 30.0 24.0 12.0 166 SWF 0014 480 5K CK 30 SWF 0021 480 5K 01 15 21 Wall 30.0 24.0 12.0 178 SWF 0021 480 5K CK 37 SWF 0027 480 5K 01 20 27 Wall 30.0 24.0 12.0 196 SWF 0027 480 5K CK 45 SWF 0034 480 5K 01 25 34 Wall 30.0 24.0 12.0 205 SWF 0034 480 5K CK 50 SWF 0040 480 5K 01 30 40 Wall 30.0 24.0 12.0 233 SWF 0040 480 5K CK 64 SWF 0052 480 5K 01 40 52 Wall 36.0 30.0 16.0 244 SWF 0052 480 5K CK 69 SWF 0065 480 5K 01 50 65 Wall 36.0 30.0 16.0 312 SWF 0065 480 5K CK 83 SWF 0077 480 5K 01 60 77 Wall 36.0 30.0 16.0 332 SWF 0077 480 5K CK 93 SWF 0096 480 5K 01 75 96 Wall 42.0 30.0 16.0 360 SWF 0096 480 5K CK 107 SWF 0124 480 5K 01 100 124 Wall 42.0 30.0 16.0 388 SWF 0124 480 5K CK 121 SWF 0156 480 5K 01 125 156 Wall 42.0 30.0 16.0 499 SWF 0156 480 5K CK 168 SWF 0180 480 5K 01 150 180 Floor 83.0 24.0 32.0 929 SWF 0180 480 5K CK 218 SWF 0240 480 5K 01 200 240 Floor 83.0 24.0 32.0 996 SWF 0240 480 5K CK 251 SWF 0302 480 5K 01 250 302 Floor 83.0 24.0 32.0 1134 SWF 0302 480 5K CK 320 SWF 0361 480 5K 01 300 361 Floor 83.0 24.0 32.0 1088 SWF 0361 480 5K CK 297 SWF 0414 480 5K 01 350 414 Floor 83.0 24.0 32.0 1248 SWF 0414 480 5K CK 377 SWF 0477 480 5K 01 400 477 Floor 83.0 24.0 32.0 1383 SWF 0477 480 5K CK 446 SWF 0515 480 5K 01 450 515 Floor 83.0 24.0 32.0 1699 SWF 0515 480 5K CK 562 SWF 0590 480 5K 01 500 590 Floor 83.0 24.0 32.0 1712 SWF 0590 480 5K CK 569 SWF 0720 480 5K 01 600 720 Floor 83.0 48.0 32.0 1543 SWF 0720 480 5K CK 485 SWF 0840 480 5K 01 700 840 Floor 83.0 48.0 32.0 1615 SWF 0840 480 5K CK 521 SWF 0960 480 5K 01 800 960 Floor 83.0 48.0 32.0 1793 SWF 0960 480 5K CK 610 SWF 1080 480 5K 01 900 1080 Floor 83.0 48.0 32.0 2060 SWF 1080 480 5K CK 744 SWF 1200 480 5K 01 1000 1200 Floor 83.0 48.0 32.0 2081 SWF 1200 480 5K CK 747 SWF 1440 480 5K 01 1200 1440 Floor 83.0 48.0 32.0 2520 SWF 1440 480 5K CK 968 10 SWF DV/DT Solutions Sinewave Filters
SWF DV/DT Solutions Selection Chart 600 V 5 khz Series 5 khz Design Type Type 1 Enclosed Catalog Number HP Max Amps Mounting Type Type 1 Dimensions (in.) H x W x D WT 5 khz Design Type Component Kit Part Number Kit Weight SWF 0003 600 5K 01 2 2.7 Wall 30.0 24.0 16.0 138 SWF 0003 600 5K CK 30 SWF 0004 600 5K 01 3 3.9 Wall 30.0 24.0 16.0 138 SWF 0004 600 5K CK 30 SWF 0006 600 5K 01 5 6.1 Wall 30.0 24.0 16.0 138 SWF 0006 600 5K CK 30 SWF 0009 600 5K 01 7.5 8.6 Wall 30.0 24.0 16.0 138 SWF 0009 600 5K CK 30 SWF 0011 600 5K 01 10 11 Wall 30.0 24.0 16.0 140 SWF 0011 600 5K CK 32 SWF 0017 600 5K 01 15 17 Wall 30.0 24.0 16.0 155 SWF 0017 600 5K CK 47 SWF 0022 600 5K 01 20 22 Wall 30.0 24.0 16.0 155 SWF 0022 600 5K CK 47 SWF 0027 600 5K 01 25 27 Wall 30.0 24.0 16.0 155 SWF 0027 600 5K CK 47 SWF 0032 600 5K 01 30 32 Wall 30.0 24.0 16.0 164 SWF 0032 600 5K CK 56 SWF 0041 600 5K 01 40 41 Wall 30.0 24.0 16.0 175 SWF 0041 600 5K CK 67 SWF 0052 600 5K 01 50 52 Wall 36.0 30.0 16.0 193 SWF 0052 600 5K CK 85 SWF 0061 600 5K 01 60 61 Wall 36.0 30.0 16.0 242 SWF 0061 600 5K CK 94 SWF 0072 600 5K 01 75 72 Wall 36.0 30.0 16.0 242 SWF 0072 600 5K CK 94 SWF 0099 600 5K 01 100 99 Wall 42.0 30.0 16.0 273 SWF 0099 600 5K CK 125 SWF 0125 600 5K 01 125 125 Wall 42.0 30.0 16.0 304 SWF 0125 600 5K CK 137 SWF 0144 600 5K 01 150 144 Wall 42.0 30.0 16.0 308 SWF 0144 600 5K CK 141 SWF 0192 600 5K 01 200 192 Floor 83.0 24.0 32.0 395 SWF 0192 600 5K CK 227 SWF 0236 600 5K 01 250 236 Floor 83.0 24.0 32.0 480 SWF 0236 600 5K CK 313 SWF 0289 600 5K 01 300 289 Floor 83.0 24.0 32.0 495 SWF 0289 600 5K CK 327 SWF 0326 600 5K 01 350 326 Floor 83.0 24.0 32.0 715 SWF 0326 600 5K CK 391 SWF 0382 600 5K 01 400 382 Floor 83.0 24.0 32.0 705 SWF 0382 600 5K CK 381 SWF 0412 600 5K 01 450 412 Floor 83.0 24.0 32.0 719 SWF 0412 600 5K CK 395 SWF 0471 600 5K 01 500 471 Floor 83.0 24.0 32.0 792 SWF 0471 600 5K CK 468 SWF 0576 600 5K 01 600 576 Floor 83.0 24.0 32.0 1086 SWF 0576 600 5K CK 588 SWF 0672 600 5K 01 700 672 Floor 83.0 48.0 32.0 1119 SWF 0672 600 5K CK 621 SWF 0761 600 5K 01 800 761 Floor 83.0 48.0 32.0 1121 SWF 0761 600 5K CK 623 SWF 0864 600 5K 01 900 864 Floor 83.0 48.0 32.0 1286 SWF 0864 600 5K CK 788 SWF 0960 600 5K 01 1000 960 Floor 83.0 48.0 32.0 1516 SWF 0960 600 5K CK 935 SWF DV/DT Solutions Sinewave Filters 11
N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI 53051 P. (262) 754-3883 F. (262) 754-3993 www.apqpower.com